192 Service Manual

192 Axle
ASM-0017E
July 2021
CONTENTS
DISCLAIMER
The official language chosen by the Product manufacturer is English. No liability is assumed as a result of translations in
other languages not in compliance with the original meaning. In case of conflicting language versions of this document, the
English original prevails. Dana shall not be liable for any misinterpretation of the content here into. Photos and illustrations
might not represent the exact product.
© Copyright 2021 Dana Incorporated
All content is subject to copyright by Dana and may not be reproduced in whole or in part by any means, electronic or other-
wise, without prior written approval.
THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.
CONTENTS
INTRODUCTION ................................................................................................................................ 5
VERSION TRACKING ................................................................................................................................... 6
MANUAL APPLICABILITY AND SUPPORTED MODELS ............................................................................. 6
SPECIFICATIONS .............................................................................................................................. 7
DEFINITION OF VIEWPOINTS ...................................................................................................................... 7
DATA PLATE ................................................................................................................................................. 7
CONVERSION TABLES ................................................................................................................................ 8
UNITS OF PRESSURE ............................................................................................................................. 8
UNIT OF WEIGHT .................................................................................................................................... 8
UNITS OF TORQUE ................................................................................................................................. 8
TORQUE SPECIFICATIONS ......................................................................................................................... 9
COARSE PITCH ....................................................................................................................................... 9
FINE PITCH .............................................................................................................................................. 9
WHEEL NUT TIGHTENING TORQUES .................................................................................................... 10
MAINTENANCE ................................................................................................................................. 11
MAINTENANCE POINTS .............................................................................................................................. 11
OIL DRAINING MANDATORY PROCEDURE ................................................................................................ 12
CENTRAL HOUSING ............................................................................................................................... 12
PLANETARY GEAR REDUCTION ............................................................................................................ 12
END-STOP PLIER SETTING ......................................................................................................................... 13
RETAINING SNAP RING FOR BORES .................................................................................................... 13
RETAINING SNAP RING FOR SHAFTS ................................................................................................... 13
MAINTENANCE INTERVALS ........................................................................................................................ 14
LUBRICANT & SEALANT SPECIFICATIONS ................................................................................................ 15
SAFETY PRECAUTIONS ................................................................................................................... 16
CHECKING WEAR AND REPLACING THE BRAKING DISKS ........................................................ 17
EXPLODED VIEW .......................................................................................................................................... 17
DISASSEMBLY ............................................................................................................................................. 18
ASSEMBLY ................................................................................................................................................... 21
CHECKING WEAR AND REPLACING THE BRAKING DISKS ........................................................ 29
EXPLODED VIEW .......................................................................................................................................... 29
DISASSEMBLY ............................................................................................................................................. 30
ASSEMBLY ................................................................................................................................................... 32
PLANETARY REDUCTION AND AXLE SHAFT ................................................................................ 37
EXPLODED VIEW .......................................................................................................................................... 37
DISASSEMBLY ............................................................................................................................................. 38
ASSEMBLY ................................................................................................................................................... 42
PINION ............................................................................................................................................... 47
EXPLODED VIEW .......................................................................................................................................... 47
DISASSEMBLY ............................................................................................................................................. 48
ASSEMBLY ................................................................................................................................................... 51
DIFFERENTIAL UNIT ........................................................................................................................ 55
EXPLODED VIEW .......................................................................................................................................... 55
DISASSEMBLY ............................................................................................................................................. 56
ASSEMBLY ................................................................................................................................................... 60
NO-SPIN DIFFERENTIAL UNIT ........................................................................................................ 67
EXPLODED VIEW .......................................................................................................................................... 67
DISASSEMBLY ............................................................................................................................................. 68
ASSEMBLY ................................................................................................................................................... 70
LIMITED SLIP DIFFERENTIAL UNIT ................................................................................................ 73
EXPLODED VIEW .......................................................................................................................................... 73
DISASSEMBLY ............................................................................................................................................. 74
ASSEMBLY ................................................................................................................................................... 77
ASM-0017E - 192 Axle Service Manual Dana Incorporated 3

BEVEL PINION ................................................................................................................................... 81
EXPLODED VIEW .......................................................................................................................................... 81
DISASSEMBLY ............................................................................................................................................. 82
ASSEMBLY ................................................................................................................................................... 88
SPECIAL TOOLS ............................................................................................................................... 99
T1 .................................................................................................................................................................. 99
T2 .................................................................................................................................................................. 100
T3 .................................................................................................................................................................. 101
T4 .................................................................................................................................................................. 102
T5 .................................................................................................................................................................. 103
T6 .................................................................................................................................................................. 105
T7 .................................................................................................................................................................. 106
T8 .................................................................................................................................................................. 107
T9 .................................................................................................................................................................. 107
T10 ................................................................................................................................................................ 108
T11 ................................................................................................................................................................ 109
T12 ................................................................................................................................................................ 110
4 Dana Incorporated ASM-0017E - 192 Axle Service Manual

INTRODUCTION
The efficiency and continued operation of mechanical units depend on constant, correct maintenance and also on efficient re-
pair work, should there be a break-down or malfunction. The instructions contained in this manual have been based on a com-
plete overhaul of the unit. However, it is up to the mechanic to decide whether or not it is necessary to assemble only individual
components, when partial repair work is needed. The manual provides a quick and sure guide which, with the use of photogra-
phs and diagrams illustrating the various phases of the operations, allows accurate work to be performed.All the information
needed for correct disassembly, checks and assembly of each individual component is set out below. In order to remove the
differential unit from the vehicle, the manuals provided by the vehicle manufacturer should be consulted. In describing the fol-
lowing operations it is presumed that the unit has already been removed from the vehicle.
IMPORTANT: In order to facilitate work and protect both working surfaces and operators, it is advisable to use proper equip-
ment such as: trestles or supporting benches, plastic or copper hammers, appropriate levers, pullers and specific spanners or
wrenches. Before going on to disassemble the parts and drain the oil, it is best to thoroughly clean the unit, removing any en-
crusted or accumulated grease.
INTRODUCTORY REMARKS: All the disassembled mechanical units should be thoroughly cleaned with appropriate products
and restored or replaced if damage, wear, cracking or seizing have occurred. In particular, thoroughly check the condition of
all moving parts (bearings, gears, ring gear and pinion, shafts) and sealing parts (o-rings, oil shields) which are subject to major
stress and wear. In any case, it is advisable to replace the seals every time a component is overhauled or repaired. During as-
sembly, the sealing rings must be lubricated on the sealing edge. In the case of the ring gear and pinion, replacement of one
component requires the replacement of the other one. During assembly, the prescribed pre-loading, backlash and torque of
parts must be maintained.
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of all specific tools required for maintenance and repair work can
be found at the end of this manual ; spare parts may be ordered either from the vehicle manufacturer or directly from the Service
Centers or Authorized Distributors of Dana Holding Corporation.

VERSION TRACKING
VERSION TRACKING
FILE NAME REVISION DATE CHANGES DESCRIPTION

192Axle_10122012 00 10/12/2012 Document issued
- Updated layout.
ASM-0017E_Rev.01 192 01 16/11/2018 - Added NO-SPIN DIFFERENTIAL UNIT p. 67.
- Added BEVEL PINION p. 81
- Changed DATA PLATE p. 7
- Updated END-STOP PLIER SETTING p. 13
ASM-0017E_Rev.02 192 02 28/02/2019
- Changed MAINTENANCE INTERVALS p. 14
- Updated LIMITED SLIP DIFFERENTIAL UNIT p. 73.
- Updated PLANETARY REDUCTION AND AXLE SHAFT
ASM-0017E_Rev.03 192 03 30/07/2021
p. 37.
MANUAL APPLICABILITY AND SUPPORTED MODELS
MODELS
All 192 Axles

SPECIFICATIONS
DEFINITION OF VIEWPOINTS
DATA PLATE
TYPE SERIAL No.
MODEL RATIO
MANUFACTURED BY DANA ITALIA S.p.a.

MADE IN ITALY
1 - Model Number
2 - Reduction ratio
3 - Serial number
4 - Axle number

CONVERSION TABLES
CONVERSION TABLES
UNITS OF PRESSURE
Atm Bar MPa Pa PSI
Atm 1 1 0,1 105 14,4
Bar 1 1 0,1 105 14,4

MPa 10 10 1 106 144
Pa 0,00001 0,00001 10-6 1 -
PSI - - - - 1
UNIT OF WEIGHT
N daN kN kg lbs
1N 1 0,1 0,001 0,102 0,225
1daN 10 1 0,01 1,02 2,25
1kN 1000 100 1 102 225
1kg 9,81 0,981 0,00981 1 2,205
UNITS OF TORQUE
N·m daN·m kN·m kg·m lb·in
1N·m 1 0,1 0,001 0,102 8,854
1daN·m 10 1 0,01 1,02 88,54
1kN·m 1000 100 1 102 8854
1kg·m 9,81 0,981 0,00981 1 86,8
1 lb·in 0,1129 0,01129 0,0001129 0,01152 1

TORQUE SPECIFICATIONS
COARSE PITCH
SIZE OF BOLT TYPE OF BOLT
8.8 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270
M6 x 1 mm 9,5 - 10,5 N·m 10,5 - 11,5 N·m 14,3 - 15,7 N·m 15,2 - 16,8 N·m 16,2 - 17,8 N·m 18,1 - 20 N·m
M8 x 1,25 mm 23,8 - 26,2 N·m 25,6 - 28,4 N·m 34,2 - 37,8 N·m 36,7 - 40,5 N·m 39 - 43 N·m 43,7 - 48,3 N·m
M10 x 1,5 mm 48 - 53 N·m 52 - 58 N·m 68 - 75 N·m 73 - 81 N·m 80 - 88 N·m 88 - 97 N·m

M14 x 2 mm 129 - 143 N·m 143 - 158 N·m 182 - 202 N·m 200 - 221 N·m 221 - 244 N·m 238 - 263 N·m
FINE PITCH
SIZE OF BOLT TYPE OF BOLT
8.8 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270
M8 x 1 mm 25,7 - 28,3 N·m 27,5 - 30,5 N·m 36,2 - 39,8 N·m 40 - 44 N·m 42,8 - 47,2 N·m 47,5 - 52,5 N·m
M10 x 1,25 mm 49,4 - 54,6 N·m 55,2 - 61 N·m 71,5 - 78,5 N·m 78 - 86 N·m 86 - 94 N·m 93 - 103 N·m

WHEEL NUT TIGHTENING TORQUES

Wheel nut tightening torques recommended from rim's O.E.M. with reference to the quality of the rim's material.
WHEEL NUT TIGHTENING TORQUES
RECOMMENDED WHEEL NUTS TORQUE
CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY
ST 37 **ST 52
M18X1,5 mm 330 N·m 460 N·m

WHEEL NUTS WITH
INTEGRATED M20X1,5 mm 490 N·m 630 N·m
SPHERICAL COLLAR
M22X1,5 mm 630 N·m 740 N·m
FLAT COLLAR WHEEL M18X1,5 mm 270 N·m 360 N·m

NUTS WITH SEPARATE
M20X1,5 mm 360 N·m 450 N·m
SPHERICAL LOCK
WASHER M22X1,5 mm 460 N·m 550 N·m
M18X1,5 mm 260 N·m 360 N·m

WHEEL NUTS WITH
INTEGRATE SEAT M20X1,5 mm 350 N·m 500 N·m
CAPTIVE WASHER
M22X1,5 mm 450 N·m 650 N·m
**RIM'S MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATION. IT IS THE OPTIMUM MA-

TERIAL FOR TIGHTENING THE RIM TO THE HUB.
NOTE:
The wheel nut tightening torque is related only on nut thread and stud thread dry. (Without oil or any lubricant).
NOTE:
The wheel nut tightening torque takes into consideration not only the nut + stud characteristics, but also the quality of
the rim material.

MAINTENANCE
MAINTENANCE POINTS
2 2
1 3
2
1 3
1 - Oil fill plug
2 - Oil drain plug
3 - Check level plug

OIL DRAINING MANDATORY PROCEDURE
OIL DRAINING MANDATORY PROCEDURE
WARNING
• Do not attempt any maintenance if the axle is hot (40-50°C / 104-122°F). Hot oil and components can cause personal injury.
Avoid skin contact. Wear protective gloves and glasses.
• Make sure all fluids are contained during inspection, maintenance, tests, adjustment and repair of the product. Prepare a
suitable container to collect the fluid before removing any component containing fluids. Dispose of all fluids following legal and
local regulations.
CENTRAL HOUSING
Before draining oil it is mandatory to loosen the oil filling plug or the breather (if present), and wait until the internal pressure is
completely released. Remove the oil draining plug and drain oil only when the pressure is completely released.
PLANETARY GEAR REDUCTION

Before draining oil it is mandatory to rotate the planetary gear reduction in order to move the oil plug in filling position, then
loosen the oil plug and wait until the internal pressure is completely released. Remove the oil plug and drain oil only when the
pressure is completely released.

END-STOP PLIER SETTING
END-STOP PLIER SETTING
RETAINING SNAP RING FOR BORES RETAINING SNAP RING FOR SHAFTS
d1
d1
2019 2019
1 - Measure the bore diameter of circlip (or snapring) "d1"; 1 - Measure the shaft diameter of circlip (or snapring) "d1";
2 - Pre-set the caliber at value "Dmin" ("Dmin" = "d1" x 0,99); 2 - Pre-set the caliber at value "Dmax" ("Dmax" = "d1" x
3 - Fix it with the screw on caliber (see picture - Point A); 1,01);
4 - Put the snap ring into the plier; 3 - Fix it with the screw on caliber (see picture - Point A);
5 - Close it until the end-stop bolt allows; 4 - Put the snap ring into the plier;
6 - Adjust the end-bolt in order to match the external diame- 5 - Open it until the end-stop bolt allows:
ter of the snap ring with "Dmin" value; 6 - Adjust the end-bolt in order to match the internal diameter
7 - Scrap the snap ring used for the end-stop plier calibra- of the snap ring with "Dmax" value;
tion. 7 - Scrap the snap ring used for the end-stop plier calibra-
tion.
A
CAUTION
This procedure is aligned with DIN standard. In any case,
DIN 471 regulation prevails.
CAUTION
End-bolt Snap ring replacement is mandatory if they are removed wi-
thout pre-setted plier.
CAUTION
This procedure is aligned with DIN standard. In any case,
DIN 472 regulation prevails.
CAUTION
Snap ring replacement is mandatory if they are removed wi-
thout pre-setted plier.

ASM-0017E - 192 Axle Service Manual
1st CHANGE /
OPERATION COMPARTMENT FREQUENCY (whs) LUBRICANTS REMARKS
CHECK (whs)
Carefully clean oil magnetic plugs and
Oil level check All 10 whs Monthly For details see below
speed sensors**.
Central body with standard
bevel gear - UTTO (API GL4) (1) If with limited slip differential, and/or
J20/C; or gear: SAE 80W/90 wet brakes, use LS additivated oils.
Differential 100-250 whs max. * (API GL4 or GL5) (1) Carefully clean oil magnetic plugs and
Central body with hypoid bevel speed sensors **.
gear - SAE 80W/90 (API GL5) (1)
UTTO (API GL4) J20/C; or
Carefully clean oil magnetic plugs and
Oil Change Hub Reduction 100-250 whs max. * 1000 whs gear: SAE 80W/90 (API GL4
speed sensors **.
or GL5)
Gears and wet discs clutch
- ATF oil e.g. GM Dexron IIE, Carefully clean oil magnetic plugs and
Dexron III speed sensors **.
Dropbox / Transmission** 100-250 whs max.*
CAUTION
Only gears - UTTO J20/C, or * in accordance with Machine Service

gear: SAE 80W/90 (API GL4 requirements.
or GL5)
Negative brake (SAHR) For hydraulic actuations not applicable
(brakes, SAHR, 100% diff.
Adjustment 100 whs Every 500 whs
Following table refers only to axles without forced lubrication.
lock, etc.) use ATF oil e.g. GM DOT brake fluids oils are NOT compati-
Service brake
Dexron IIE, Dexron III ble w/ std oils.
Check for any damage or corrosion of
Tightening Wheel nuts 10 whs Every 200 whs No lubricant allowed
treads or mating surfaces.
MAINTENANCE INTERVALS
King Pin Tapered Roller

10 whs Supply grease until clean grease is vis-
Bearings NLGI2 EP or NLGI3 EP
ible from outside.
Seals 10 whs Normal work – Weekly
Grease performance level acc. to: Ac-
Greasing or
cording to DIN 51825 level KP2K-30
King Pin Bushings 10 whs Severe duty – Daily
NLGI2 EP or NLGI3 EP with (NLGI2) or KP3K-20 (NLGI3); ASTM
Moly Addittive D4950 NLGI2 GC-LB
MAINTENANCE INTERVALS
Trunnion Bushings 10 whs

In case of severe duty, half oil change intervals must be applied.
In case of extreme enviroments, chatter noise, reduce oil change intervals accordingly.
In case of extremely low ambient temperatures (<-20°C), use appropriate oils w/ low viscosity: UTTO J20/D (std Bevel Gears), SAE 75W/90 API GL5 LS (Hypoid Bevel
Dana Incorporated
Gears: i.e. axle models 192, 193, 194).
API GL5: Acc. To MIL L-2105-B
See PSB 00279 (latest update) for more info regarding lubricants and viscosity grades. document rev.02_18122018
**Where present
14
LUBRICANT & SEALANT SPECIFICATIONS
LUBRICANT & SEALANT SPECIFICATIONS

1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with
similar products marketed by different brand names with different trade marks.
LOCTITE 204 (DRILOC)
Preapplied threadlocking adhesive that provides excellent resistance to vibration loosening on any threaded fastener including
nuts. Designed for plated and stainless steel fasteners. High dried adhesion, high strength.
LOCTITE 242
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Before using it,
completely remove any lubricant by using the specific activator.
LOCTITE 243
The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
LOCTITE 270
Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any lubricant by using
the specific activator.
To remove parts, it may be necessary to heat them at 80° C approximately.
LOCTITE 275
Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts, for pipe sealing
and for protecting parts against tampering; suitable for sealing coupling surfaces with a maximum diametrical clearance of 0.25
mm.
LOCTITE 510
Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can seal clearances
between flanges up to 0.2 mm.
LOCTITE 577
Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using it, remove any
lubricant with the specific activator. After polymerisation, disassembly may result rather difficult, so heating may be necessary
for larger diameters.
LOCTITE 638
Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue together parts with cle-
arance ranging between 0.1 and 0.25 mm.
LOCTITE 648
Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue together parts with
radial clearance below 0.1 mm.
AREXONS (REPOSITIONABLE JOINTING COMPOUND FOR SEALS)
Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer diameter of sealing
rings for rotating shafts with outer metal reinforcement.
SILICONE
Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and physical elements.
Polymerises with non-corrosive dampness.
TECNO LUBE/101 (SILICONE-BASED GREASE)
Highly adhesive synthetic grease, with silicone compounds added.
Applied to adjustment screws with hole communicating with oil-type fluids.
Used when frequent adjusting is required.
MOLIKOTE (DOW CORNING)
Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent sticking and oxi-
dation of parts that are not lubricated on a regular basis.
(LITHIUM-BASED) GREASE
Applied to bearings, sliding parts and used to lubricate seals or parts during assembly.

SAFETY PRECAUTIONS
1 - During all operations described in this manual, the axle should be fastened onto a trestle, while the other parts
mentioned should rest on supporting benches.
2 - When removing one of the arms, an anti-tilting safety trestle should be placed under the other arm.
3 - When working on an arm that is fitted on the machine, make sure that the supporting trestles are correctly po-
sitioned and that the machine is locked lengthways.
4 - Do not admit any other person inside the work area; mark off the area, hang warning signs and remove the igni-
tion key from the machine.
5 - Use only clean, quality tools; discard all worn, damaged, lowquality or improvised wrenches and tools. Ensure
that all torque wrenches have been checked and calibrated.
6 - During maintenance operations, always wear protective glasses, safety footwear, protective gloves and all
P.P.E. (Personal Protective Equipment) in function of the risks which the workers may be exposed to.
7 - Should you stain a surface with oil, remove marks straight away.
8 - Dispose of all lubricants, seals, rags and solvents once work has been completed. Treat them as special waste
and dispose of them according to the relative law provisions obtaining in the country where the axles are being
overhauled.
9 - Make sure that only weak solvents are used for cleaning purposes; avoid using turpentine, dilutants and toluol,
xylolbased or similar solvents; use light solvents such as Kerosene, mineral spirits or water-based, environment
friendly solvents.
10 - For the sake of clarity, the parts that do not normally need to be removed have not been reproduced in some
of the diagrams.
11 - For agricultural axles, the terms RIGHT and LEFT refer to the position from operator’s seat. For construcition
axle, the terms RIGHT and LEFT refer to the position outside facing the machine (with the input drive facing
forward).
12 - Follow all safety instructions in the Original Equipment Manufacturer (OEM) manual that came with the vehicle.
13 - Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE
p. 12.
Indicates an imminently hazardous situation

DANGER which, if not avoided, will result in death or se-
rious injury.
Indicates an imminently hazardous situation
WARNING which, if not avoided, could result in death or se-
rious injury.
Indicates a situation which, if not avoided, may
CAUTION result in damage to components.
Indicates information which may make product

NOTICE service easier to perform.

CHECKING WEAR AND REPLACING THE BRAKING DISKS
EXPLODED VIEW
22 21
23
19
20
18
17
1 2
4
3 16
15
5
14
6 7
13
8
9
24
10
11
12

DISASSEMBLY
DISASSEMBLY
19
CAUTION
Before draining oil, release the internal pressure, for details
see OIL DRAINING MANDATORY PROCEDURE p. 12
CAUTION
Make sure all fluids are contained during inspection, main-
tenance, tests, adjustment and repair of the product. Prepa-
re a suitable container to collect the fluid before removing
any component containing fluids. Dispose of all fluids fol- FIGURE 3: Loosen screws (19) in an alternate manner and re-
lowing legal and local regulations. move them.
CAUTION
19
Hot oil and components can cause personal injury. Avoid
skin contact.
FIGURE 4:
5 1
FIGURE 1: REPLACING THE BRAKING DISKS

Sling the arm to be removed and connect it to a hoist.
Loosen and remove screws and nuts.
FIGURE 5: Move the cylinder (5) outwards while supporting

the Bellevillewashers (1).
Remove the Belleville washers (1) and note down direction of
assembly.
24
FIGURE 2: Remove arm (24) together with brakes and axle
shafts; lay down the arm vertically.

DISASSEMBLY
7
4
FIGURE 6: Take off screws of counterwasher. FIGURE 9: Remove O-rings (2, 4) from the piston (3).
NOTE:
The O-rings (2, 4) must be replaced each time the unit is
disassembled.
18
8
17
FIGURE 7: Note down their order of assembly and remove
the counterwasher (18).
FIGURE 10: Remove braking discs (8, 17), noting down direc-
tion of assembly.
NOTE:
If disks are not to be replaced, avoid changing their posi-
tion.
FIGURE 8: Slowly introduce low-pressure compressed air

through the connection member for the negative brake, in or-
der to extract thepiston (3).
CAUTION
Hold the piston (3) back, as it may be suddenly ejected and
damaged.
FIGURE 11: REMOVABLE VERSION
Remove the axle shaft

DISASSEMBLY
15 14
13
FIGURE 12: Remove screw (13) and safety (14).
16
FIGURE 13: Remove pinion (16) complete with O-ring.
NOTE:
L'anello OR deve essere sostituito ad ogni smontaggio.
FIGURE 14: Unscrew and extract the braking disk clearance

adjustment crown wheel (9).

ASSEMBLY
ASSEMBLY
17
9 FIGURE 4: Lightly lubricate the first steel braking disk (17),

then install it on the arm.
FIGURE 1: Lubricate the threaded portion of the crown wheel
(9) and screw it down into the arm as far as it will go.
24
9
FIGURE 5: Cecking wear braking disks.
New:4,9mm
FIGURE 2: Lubricate and install the pinion in the slot provided Change: less than 4,5mm
on the arm (24), inserting the toothing into crown wheel (9).
FIGURE 6: Lubricate the first friction disk (8) and install it on

FIGURE 3: Install the axle shaft. the axle shaft .
Complete the assembly, alternating steel disks and friction
disks.

ASSEMBLY
22 3
FIGURE 7: FIGURE 10: Fit O-rings (2, 4) onto the piston (3).
Lubricate the piston and the O-rings and install the unit into
the cylinder (5).
22
NOTE:
Piston relief «C» must face downwards.
2 3
FIGURE 8: Remove the breather (22) from the cylinder.
4
FIGURE 11:
5 3
TECNOLUBE
FIGURE 9: Grease with TECNOLUBE.

TECNOLUBE
FIGURE 12: Grease the diameter with TECNOLUBE.

ASSEMBLY
5
22
FIGURE 13: Using a plastic hammer, ram the piston (3) into FIGURE 16: Assemby the breather (22).
the cylinder (5).
NOTE: 6
Lightly hammer all around the edge in an alternate se-
quence.
18
FIGURE 17: Check integrity and position of the cylinder's O-

ring (6).
FIGURE 14: Insert the intermediate disk (18).
18
FIGURE 18: Check integrity and position of the arm's O-ring.
FIGURE 15: Lock the intermediate disk (18), tightening the

screws (7) with a dynamometric wrench set to a torque of 23
- 26 N·m.

ASSEMBLY
out side
GLႇHUHQWLDOVLGH
FIGURE 19: Position the Belleville washers (1) and engage FIGURE 22: Lock the cylinder (5), tightening the screws with
the cylinder (5). a dynamometric wrench set to a torque of 82 - 91 N·m.
NOTE:
Check the sense of direction of washers (1) and relative
centring.
FIGURE 23: Install the complete arm.
FIGURE 20: Lubricate the O-ring and position the cylinder on

the studs and fastening.
19
FIGURE 24: Temporarily lock the arm with nuts previously
coated with Loctite 242; tighten lightly to make the unit touch
TECNOLUBE
the main body.
FIGURE 21: Preload the spring and tighten screws (19) in two
stages, using the criss-cross method.

ASSEMBLY
13
FIGURE 25: Check the flatness of the arms, using tool T1 (for FIGURE 28: Rotate the adjustment pinion (13) anticlockwise
detail see T1 p. 99) then lock the arms into their final position, (±) to eliminate all existing clearance between the braking di-
using screws adequately coated with Loctite 242. sks.
Rotate up to a torque of 8-10 N·m.
LOCTITE 242
14
+
--
13
FIGURE 26: Torque wrench setting: 283 - 312 N·m.

FIGURE 29: Rotate pinion (13) clockwise to obtain the accu-
NOTE: rate clearance.
Tighten using the criss-cross method.
NOTE:
Every turn of the pinion produces a clearance of 0.25mm.
P Gap 1,00 mm = 4 turns
Gap 0,75 mm = 3 turns
FIGURE 27: Connect an external pump to the union piece “P”

of the negative brake and introduce pressure to 15-30 bar.
FIGURE 30: Release pressure, fit the catch and lock with
screw coated with Loctite 242.
Tighten screw to a torque of 20-30 N·m.

ASSEMBLY
14
12
13
15
FIGURE 31: FIGURE 34: Using a wrench, tighten the screws (12) in an al-
ternate sequence by 1/4 turn at a time so as to compress the
Belleville washers (1) and disengage the braking disks.
IMPORTANT:
TIGHTEN MAX. BY ONE TURN.
FIGURE 32: MANUAL EMERGENCY RELEASE

Loosen nuts (11) of screws (12) provided for the mechanical
and manual release of the braking units, then move the nuts
backwards by approx. 8 mm.
FIGURE 35: ADJUSTMENT AFTER MANUAL RELEASE

1 Remove screws complete with nuts and seals.
18 Replace seals, apply silicone-based Tecno Lube /101 grease
to the screws and install all parts into the arm.
11
10
11
12
10 12
FIGURE 33: Tighten screws (12) so as to fasten them onto the
pressure plate (18).
FIGURE 36:

ASSEMBLY
FIGURE 37: Adjust screws (12) to obtain a jut of 31 ± 0.5 mm

in relation to the arm.
FIGURE 38: Lock into position with nuts (11).
CAUTION
Hold screws (12) into position while locking the nuts (11); af-
ter locking, check the jut of screws (12) once more.

CHECKING WEAR AND REPLACING THE BRAKING DISKS
EXPLODED VIEW
10
8
7
5
6
4
11
3
2
1
12

DISASSEMBLY
DISASSEMBLY
CAUTION
see OIL DRAINING MANDATORY PROCEDURE p. 12 10
CAUTION
any component containing fluids. Dispose of all fluids fol- FIGURE 3: Remove the Belleville washer (10) and write down
lowing legal and local regulations. direction of assembly.
CAUTION 11
skin contact.
FIGURE 4: Remove the o-ring (11).
10
FIGURE 1: Sling the arm to be removed and connect it to a

hoist.
FIGURE 5: Remove the Belleville washer (10) and write down

direction of assembly.
FIGURE 2: Remove arm together with brakes and axle shafts;

lay down the arm vertically.

DISASSEMBLY
9
7
FIGURE 6: Slowly introduce low-pressure compressed air FIGURE 9: Remove the o-ring (7).
through the connection member for the negative brake, in or-
der to extract the piston (9). NOTE:
The o-rings (7) must be replaced each time the unit is di-
sassembled.
CAUTION
Hold the piston (9) back, as it may be suddenly ejected and
4
damaged.
8
7
FIGURE 10: Remove braking discs (4), noting down direction

of assembly.
FIGURE 7: Remove o-rings (7, 8) from the piston (9). NOTE:

If disks are not to be replaced, avoid changing their posi-
NOTE: tion.
The o-rings (7, 8) must be replaced each time the unit is
disassembled.
FIGURE 8: Write down the position of the brake pusher plate

(5) and remove it.

ASSEMBLY
ASSEMBLY
4
FIGURE 14: Insert the intermediate disk (4). Before installing

the last brake disc and the intermediate disc, spread grease
FIGURE 11: Lightly lubricate the first steel braking disk (4), over the contact surfaces to hold them in position while
then install it on the arm (6). mounting on the central housing.
4
6
FIGURE 12: Lubricate the first friction disk (4) and install it on FIGURE 15: If needed, install the pin (6).
the axle shaft.
Complete the assembly, alternating steel disks and friction
disks.
7
FIGURE 16: Install the new o-ring (7). Grease before instal-
B
ling.
FIGURE 13: Oval holes “B” of friction disks must be lined up.

ASSEMBLY
5 10
FIGURE 17: Position the brake pusher plate (5) in the arm. FIGURE 20: Position the Belleville washers (10) and engage
the cylinder.
NOTE:
Refer and keep to the positions marked during disassem- NOTE:
bly. Check the sense of direction of washers (10) and relative
centering.
8 11
7
FIGURE 18: Fit o-rings (7, 8) onto the piston (9).

FIGURE 21: Install the new o-ring (11). Grease before instal-
ling.
10 10
FIGURE 19: Using a plastic hammer, ram the piston (9) into
the cylinder.
FIGURE 22: Position the Belleville washers (10) and engage
NOTE: the cylinder, spread grease over the contact surfaces to hold
Lightly hammer all around the edge in an alternate se- them in position.
quence.
NOTE:
Check the sense of direction of Belleville washers (10)
and relative centering.

ASSEMBLY
FIGURE 23: Check integrity and position of the arm's o-ring FIGURE 25: RELEASE
(11); install the complete arm. Loosen nuts (2) of screws (1) provided for the mechanical and
manual release of the braking units, then move the nuts back-
NOTE: wards by approximately 8 mm.
To assist axle shaft centering, slightly move the wheel
hub.
Loctite 242 FIGURE 26: RELEASE

283 - 312 N·m Tighten screws (1) so as to fasten them onto the pressure pla-
FIGURE 24: Check the flatness of the arms, using tool T2; te (5).
then lock the arms into their final position, using screws ade-
quately coated with Loctite 242.
Torque wrench setting: 283 - 312 N·m.
NOTE: 1
FIGURE 27: RELEASE

Using a wrench, tighten the screws (1) in an alternate sequen-
ce by 1/4 turn at a time so as to compress the Belleville wa-
shers (10) and disengage the braking disks.
CAUTION
Tighten maximum by one turn.

ASSEMBLY
3
2
FIGURE 28: ADJUSTMENT

Remove screws complete with nuts and seals. Replace seals,
apply silicone-based Tecno Lube /101 grease to the screws
and install all parts into the arm.
34 mm

Adjust screws (1) to obtain a distance of 34 mm in relation to
the arm.

Lock into position with nuts (2).
CAUTION
Hold screws (1) into position while locking the nuts (2); after
locking, check the distance of screws (1) once more.

PLANETARY REDUCTION AND AXLE SHAFT
EXPLODED VIEW
3
5
31
1 6 7 14
2 8 12
15
4 16
22 23
26
18
17
9
19 10
11 13 19
30
28
20 20
25
29
27
23 24
21
28A

DISASSEMBLY
DISASSEMBLY
18
CAUTION
CAUTION
any component containing fluids. Dispose of all fluids fol- FIGURE 3: Remove the cover (18).
lowing legal and local regulations.
CAUTION
skin contact.
18 21
13
FIGURE 4: HALF SHAFT TWO PIECES VERSION

Remove the pinion (13).
FIGURE 1: Remove the locking screws (21) of planetary co-

ver (18).
28

Remove the axle half shaft (28).
18
FIGURE 2: Using two screwdrivers or two levers inserted in
the slots provided, pry the planetary cover (18) away from the
wheel hub (3).

DISASSEMBLY
12 9
28A
FIGURE 6: HALF SHAFT ONE PIECES VERSION FIGURE 9: Using an extractor and applying a counter pres-
Remove the axle half shaft (28A). sure to the screws (9), disengage the crown wheel (12) from
the hub (4).
9
12
FIGURE 7: Loosen the nuts (11) and remove them.

FIGURE 10: Remove the crown (13).
10
FIGURE 8: NOT PRESENT ON ALL MODELS

Remove the safety flange (10). FIGURE 11: Sling the hub (4) and connect it to a hoist; with
the help of a hammer, shift the hub (4) and the external bea-
ring (31).

DISASSEMBLY
31
15 14
4
FIGURE 12: Extract the hub (4) complete with external bea- FIGURE 15: Remove the safety spring rings (15) of the plane-
ring (31). tary gears (14).
CAUTION
4 1 MANDATORY PROCEDURE
Set the pliers following the correct procedure shown in
END-STOP PLIER SETTING p. 13.
WARNING
Removal of the snap rings can cause personal injuries. You
must wear appropriate safety equipment. To avoid injury to
eyes, wear eye protection equipment.
FIGURE 13: Remove the internal bearing (2) and the hub (4).
14
FIGURE 16: Remove the planetary gears (14).

FIGURE 14: Using an extractor, remove the snap ring (29).
NOTE:
NOTE: Note down direction of assembly of planetary gears.
Note down the direction of assembly of snap ring.

DISASSEMBLY
29
FIGURE 17: Only if necessary. FIGURE 20: Remove the external thrust blocks of bearings,
Using an extractor, remove the shim washer (29) from the pla- using a pindriver.
net carrier.
NOTE:
Hammer in an alternate sequence to prevent crawling
1 4 and deformation of the thrust blocks.
FIGURE 18: Remove the snap ring (1) from the hub (4).
NOTE:
Note down direction of assembly. FIGURE 21: Remove the internal thrust blocks of bearings,
using a pin-driver.
CAUTION NOTE:
Hammer in an alternate sequence to prevent crawling
The snap ring may not be reused.
and deformation of the thrust blocks.
FIGURE 19: Remove the internal bearing (10).

ASSEMBLY
ASSEMBLY
17
4
T2
FIGURE 25: Only if shim washer has previously been remo-

ved. Apply a sealant for removable seals to the outer surface
FIGURE 22: Position the wheel hub (4) under a press; lubri- of the shim washer (17) and, using a driver, fit it into the pla-
cate the seat of the external bearing and, using tool T2 (for netary gear cover (18).
detail see T2 p. 100), install the thrust block of the bearing (2).
14
1
T3
FIGURE 26: Fit the planetary gear (14) onto the planetary gear
FIGURE 23: Install the bearing (2). Apply an appropriate sea- cover(4).
lant to the outer surface of the snap ring (1).
Position the snap ring (1) into the hub (4).
Position tool T3 (for detail see T3 p. 101) and press the snap CAUTION
ring (1) down into its seat.
The jointed portion of the internal ring of the bearings must
face the bottom of the pin.
NOTE:
Check orientation of the ring.
31
T2
FIGURE 24: Turn the hub (4) upside down, lubricate the seat
of the bearing and, using tool T2 (for detail see T2 p. 100), in-
stall the thrust block of the bearing (31).

ASSEMBLY
15
14
T4
FIGURE 27: Lock into position the planetary gears (14) with FIGURE 29: Pay particular attention to the direction of as-
the snap rings (15). sembly of the rings.
CAUTION
MANDATORY PROCEDURE 4
WARNING
Personal injury can result when installing snap ring. The ap-
propriate safety equipment must be worn. To avoid injury to 1
your eyes, wear protective glasses during this procedure.
FIGURE 30: Grease the snap ring (1) and the hub of the arm.
Install the wheel hub (4).
29
T4
FIGURE 28: Lubricate and fit the snap ring (29) onto tool T4
(for detail see T4 p. 102) install the rings into the arm. 31
FIGURE 31: Install the external bearing (31).

ASSEMBLY
10
FIGURE 32: Move the bearing to the limit stop by hammering FIGURE 35: STANDARD NUTS MODELS:
lightly all around the edge. Using Tecno Lube /101, grease the surface of the safety flan-
ge (10) that touches the crown wheel.
Install the security flange (10).
12
NOTE:
Safety plate only for standard nuts models.
11
FIGURE 33: Install the crown wheel (12).
FIGURE 36: STANDARD NUTS MODELS:

Coat the nuts (10) with Loctite 242 and screw them.
Tighten nuts (10) in two stages, using the criss-cross method.
Initial torque wrench setting: 120 N·m
Final torque wrench setting: 255 - 285 N·m
12 NOTE:
If studs have been removed or got loose during nuts (4)
removal, clean the thread in the arm and replace the
studs tightening to 70 - 90 N·m.
FIGURE 34: Install the crown wheel (12) and, using a driver
with adequate diameter, fasten it onto the hub of the arm.

ASSEMBLY
11
28
FIGURE 37: FLANGED NUTS MODELS: FIGURE 39: HALF SHAFT TWO PIECES VERSION
Tighten nuts (10) in two stages, using the criss-cross method. Install the axle shaft (28), making sure that it is properly inser-
Initial torque wrench setting: 120 N·m ted into braking disks and differential unit.
Final torque wrench setting: 366 - 404 N·m
IMPORTANT:
DON’T USE THE SAFETY PLATE ON FLANGED NUTS MO-
DELS.
NOTE:
If studs have been removed or got loose during nuts (4)
removal, clean the thread in the arm and replace the
studs tightening to 70 - 90 N·m.
13

Lubricate the pinion and insert them (13).
FIGURE 38: Check the continuous rolling torque on the hub.

Torque 10-30 N·m.
28A
FIGURE 41: HALF SHAFT ONE PIECES VERSION

Install the axle shaft (28A), making sure that it is properly in-
serted into braking disks and differential unit.

ASSEMBLY
FIGURE 42: Check the condition and position of the O-ring

(6).
18
FIGURE 43: Fit the planetary gear cover (18) onto the wheel
hub (4).
FIGURE 44: Torque wrench 40-50N·m.

PINION
EXPLODED VIEW
10
7 9
8
6
11
12
14 13
5
1 2 3 15
16
18 17
19
20
21
23
22

DISASSEMBLY
DISASSEMBLY
CAUTION
CAUTION A
tenance, tests, adjustment and repair of the product. Prepa- T5
any component containing fluids. Dispose of all fluids fol- FIGURE 3: Lock into position T5 (for detail see T5 p. 103) with
lowing legal and local regulations. a screw (A).
CAUTION
skin contact.
T5
FIGURE 4: Stop wrench T5 (for detail see T5 p. 103) and ro-

tate the pinion so as to release and remove the ring nut (19).
FIGURE 1: Remove the screws (22)
15
19
FIGURE 5: Remove pinion lock nut (19).
FIGURE 2: Disjoin the cover (1) from the central body (15)

DISASSEMBLY
16
FIGURE 6: With the help of a puller, extract the pinion (16) FIGURE 9: Remove the thrust block of the external bearing.
complete with the internal bearing, the distance piece and
shims.
NOTE:
The thrust blocks of the bearings remain in the central
body.
FIGURE 10: Insert a drift in the appropriate holes.
16
18
FIGURE 7: Remove the pinion (16), shims (3, 4) and distance
piece (17).
S1
S
FIGURE 11: Remove the thrust block of the internal bearing

(9) as well as the shim washers (14).
FIGURE 8: Refer and keep to the positions marked during di-

sassembly.

DISASSEMBLY
FIGURE 12: Remove the snap ring (11).
CAUTION
MANDATORY PROCEDURE
WARNING
12
11
FIGURE 13: Remove the cap (12).

ASSEMBLY
ASSEMBLY
16
I=133mm
5
36mm
FIGURE 16: Check nominal dimension “I” as marked on the
pinion. Add up to or subtract from “I” the variation indicated
FIGURE 14: CALCULATING PINION CENTRE DISTANCE as “Y” to obtain the actual centre distance “I”.
Using a faceplate, reset a centesimal comparator “DG” on a EXAMPLE: I = 133 - 0.1 = 129.9
calibrated block (whose known thickness is 36 mm).
Preload the comparator by about 3 mm. NOTE:
A8 = X = Match part number
5
D
I=133 D S
170,2
FIGURE 15: Bring inner bearing (9), complete with thrust
block, under comparator “DG”. FIGURE 17: S = 170,2 - ( I + D )
S = 170,2 - (132,9 + 36,65 ) = 0,65mm
CAUTION
15
Press the thrust block centrally and carry out several mea-
surements by rotating the thrust block.
EXAMPLE: 36 + 0,65 = 36,65 = “D”.
T6
S
5
FIGURE 18: Using special tool T6 (for detail seeT6 p. 105).
Partially insert the thrust block of the external bearing (5).

ASSEMBLY
5
18
FIGURE 19: Connect the tension rod to the press and move FIGURE 22: Remove the comparator and take out tool and
the thrust block of the external bearing (18) into its seat. bearing kits from the main body.
Disconnect the press and remove the tension rod. Reinstall every part, also introducing a distance piece betwe-
en bearings (5, 18). Tighten the entire pack by hand.
NOTE:
Before starting the next stage, make sure that the thrust
block has been completely inserted into its seat.
15 T7
5
T7
FIGURE 23: Introduce depth comparator “DDG” in tool T7

(for detail seeT7 p. 106) and measure deviation “H” from the
18 previous reset.
FIGURE 20: CALCULATING PINION BEARINGS ROLLING EXAMPLE: H = A - B = 1.19 mm.
TORQUE
Introduce tool T7 (for detail seeT7 p. 106) complete with be-
arings (18, 5) into the main body (15); tighten by hand until a
rolling torque is definitely obtained.
T7 S1
4
FIGURE 24: Deviation “H” must be added to a set value of
0.12--0.15 mm to make up the pack of shims “S1” (4) for in-
sertion between inner bearing (5) and distance piece (17).
Dimension “S1” must be rounded off to the higher 5/100.
FIGURE 21: Introduce the tracer of a depth comparator EXAMPLE: S1 = H + X = 1.19 + (0.12--0.13) = 1,33-1.35 mm.
“DDG” into either side hole of tool T7 (for detail seeT7 p. 106)
Reset the comparator with a preload of about 3 mm.

ASSEMBLY
15
5
16
5
16 17
FIGURE 25: Heat the inner bearing (5) to about 100 °C and fit FIGURE 28: Fit the pinion (16), shim “S1” (3) and distance
it to the pinion (16). piece (17) in the main body (15).
NOTE:
WARNING The finer shims must be placed in- between the thicker
ones.
Wear protective garments when handling hot objects.
NOTE:
18
Once the bearing has cooled down, lightly lubricate bea- 16
ring (5) with SAE85W90 oil.
18
FIGURE 29: Heat the external bearing (18) to a temperature

of about 100 °C and fit it on to the pinion (16) so as to com-
plete the pack as shown in the figure.
FIGURE 26: Make sure that the bearing (18) is well set. WARNING
NOTE:
Lightly lubricate bearing (18) with SAE85W90 oil.
S
FIGURE 27: Refer and keep to the positions marked during

disassembly.

ASSEMBLY
16
19
FIGURE 30: Apply Loctite 242 to the thread of the ring nut FIGURE 32: Apply onto the pinion (16) the bar-hold and with
(19) and screw the nut onto the pinion (16). the help of a torque metre, check the torque of the pinion (16).
Torque: 120-170 N·cm
CAUTION
-If torque exceeds the maximum value, then the size of shim
“S1” (3, 4) between the bearing (18) and the distance piece
(17) needs to be increased.
-If torque does not reach the set value, increase the torque
setting of the ring nut (19) in different stages to obtain a ma-
ximum value of 800 N·m.
T5 -If torque does not reach the minimum value, then the size
of shim “S1” (3) needs to be reduced.
-When calculating the increase or decrease in size of shim
FIGURE 31: Apply wrench to the ring nut (19) and bar-hold T5 “S1”, bear in mind that a variation of shim (3) of 0.01 mm
(for detail see corresponds to a variation of 60 N·cm in the torque of the
T5 p. 103) to the pinion (16). pinion (16).
Lock the wrench T5 and rotate the pinion using a dynamome-
tric wrench, up to a minimum required torque setting of 600
N·m.

DIFFERENTIAL UNIT
EXPLODED VIEW
4 5 7
3 6
8
9
30 10
11
29 12 13 15
28 14 16
26
27
17
25 18
24
22
23
21
19
20

DISASSEMBLY
DISASSEMBLY
CAUTION
CAUTION
any component containing fluids. Dispose of all fluids fol- FIGURE 3: Loosen screws in an alternate manner and remo-
lowing legal and local regulations. ve them.
18
CAUTION
skin contact.
FIGURE 4: Remove the screw (18)
FIGURE 1: Sling the arm to be removed and connect it to a

hoist.
FIGURE 5: Uniformly heat the ring nuts up to a temperature

of 80°C.
WARNING
FIGURE 2: Remove arm together with brakes and axle shafts;

lay down the arm vertically.

DISASSEMBLY
20 27
T8 17
FIGURE 6: Only if need removing or adjusting. FIGURE 9: Remove the the cover and studs.
Using special tool T8 (for detail see T8 p. 107) mark the posi-
tion of the ring nuts.
NOTE:
Remove screws and ring nut checks.
FIGURE 10: Extract the whole differential unit.
FIGURE 7: Loose the pinions and remove two of them.
20
FIGURE 11: Remove the snap ring (8).
CAUTION
MANDATORY PROCEDURE
FIGURE 8: Disjoin the cover (20) crown side.
WARNING

DISASSEMBLY
12
13
8
FIGURE 12: Remove the cap (9). FIGURE 15: If the bearing need replacing, extract the bearing
(12) from the differential carrier (13).
23
FIGURE 13: If the bearings need replacing, extract the exter-

nal thrust blocks of the bearings (12, 17) from middle cover FIGURE 16: Remove the fittin screws (16).
(20, 29).
NOTE:
Accurately check the O-ring (9).
17
23
12
13
FIGURE 17: Remove the crown (23).
FIGURE 14: NO-SPIN:If the bearing need replacing, extract

the bearing (17).

DISASSEMBLY
24
FIGURE 18: Remove the screws (24) jointing the differential FIGURE 21: Unscrew the wing nut of stay and take the no-
unit half box . spin unit to pieces in order to remove the distance piece that
prevents the axial sliding of the axle shafts.
13
FIGURE 19: Using a plastic hammer, take the half box (13) to
pieces. FIGURE 22:
NOTE:
Note down the coupling marks.
14
FIGURE 20: Extract the no-spin unit (14).

ASSEMBLY
ASSEMBLY
23
FIGURE 26: Position the crown (23) on the differential carrier

(15) and lock it with screws (24) applied with Loctite 242.
FIGURE 23: ASSEMBLY OF THE NO-SPIN DIFFERENTIAL Torque wrench setting for screws: 128-142 N·m
UNIT
Assemble the no-spin unit, inserting the distance piece and
using stay.
16
13
14
FIGURE 27: Mount the gear ring (23) and fasten it to the dif-
ferential box with screws (16).
15
FIGURE 24: NO-SPIN
Fit the no-spin unit into the differential unit half box (15). CAUTION
Centre the half box (13) and fasten.
Use only new screws.
CAUTION
Make sure the connection marks coincide.
23 16
24
FIGURE 28: Lock the gear ring (23) by tightening the screws
(16) to a torque of 128-142 N·m.
FIGURE 25: Coat the screws (24) with Loctite 270 and screw CAUTION
tight to form the differential box. Tighten screws using the
criss-cross method and a torque of 37 - 41 N·m. Use the alternate and criss-cross tightening method.

ASSEMBLY
21, 28
17
FIGURE 29: INSTALLATION OF THE DIFFERENTIAL UNIT FIGURE 32: Thoroughly check the state of the O-ring (21, 28)
Position the differential unit under a press and, using a driver and make sure that the cover is fitted with the oil discharge in
with an adequate diameter, install the first bearing (17). the lower position.
12
29
FIGURE 30: Turn the unit upside down and install the second FIGURE 33: Lock the intermediate cover (29) with the
bearing (12). journals tightened to a torque of 129 - 143 N·m.
CAUTION C
Pay particular attention; position a shim with adequate dia-
meter in order to engage the internal ring of bearing without
engaging the cage.
FIGURE 34: Tighten the two safety studs “C” into the main
body (27) and install the intermediate cover.
Lock into position with screws treated with Grease and two
service screws “V” (M16X50) locked to the same torque.
Tighten screws to a torque of 30-45 N·m.
NOTE:
FIGURE 31: Only if bearings are replaced
Check the O-Ring status.
Insert the thrust blocks of the bearings into the intermediate
covers.

ASSEMBLY
22 T8
FIGURE 35: Position the differential unit in the central body FIGURE 38: Tighten the ring nut (22) on gear ring side until
with the help of a bar and fit the middle cover. clearances between pinion and gear ring are zeroed. Then,
loosen by about 1/4 turn.
25
20
T8
FIGURE 36: Lock the intermediate cover (20) with the

journals tightened to a torque of 129 - 143 N·m. FIGURE 39: Only if ring nuts have been removed. Preload be-
arings with ring nut (25) on non-gear ring side in order to in-
crease the torque of the pinion.
27 20
C
CAUTION
In the case of used bearings, check thrust torque; in the
case of new bearings, check continuous torque.
FIGURE 37: Tighten the two safety studs “C” into the main
body (27) and install the intermediate cover (20).
Lock into position with screws two service screws “V”
(M16X50) locked to the same torque.
Tighten screws to a torque of 30-45 N·m.
NOTE:
Check the O-Ring status.
FIGURE 40: Apply torque meter TM to pinion nut and check
that torque will increase by 20-40 N·cm as a result of differen-
tial bearing preload.
Example: pinion torque: 120-130 N·cm
Pinion + differential torque: 140-170 N·cm.

ASSEMBLY
23
T8
FIGURE 41: Introduce a comparator “A” with long tracer FIGURE 44: Adjusting clearance between pinion and gear
through the hole provided for the cap. ring.
Position the tracer on the side of a tooth of the gear ring (23), To INCREASE: loosen the ring nut on gear ring side and
approximately 5 mm from the outer rim; preload by about 1 tighten the ring nut on non-gear ring side by the same
mm and zero the comparator. measure.
To DECREASE: perform the same operations inversely.
To rotate ring nuts, use special wrench T8 (for detail see T8
p. 107)
26
FIGURE 42: As you hold the pinion in position, move the gear 25
ring (23) manually in both directions to check clearance
between pinion and gear ring.
Standard clearance: 0,13 : 0,20mm FIGURE 45: Engage screw (26) in the slot next to the holes
provided for the check screws.
Coat screws (26) with Loctite 242 and tighten to a torque of
24-26 N·m.
18
22
FIGURE 43: If torque and/or pinion-gear ring clearance is not
within tolerance values and the ring nuts have not been remo-
ved, mark the position of the ring nuts (22) and remove the sa-
fety stops (18). FIGURE 46: Fit the top plug after applying repositionable
jointing compound for seals to the rims.

ASSEMBLY
FIGURE 47: Install the snap ring. FIGURE 49: Lock the cylinder, tightening the screws with a
dynamometric wrench set to a torque of 82-91 N·m.
CAUTION
MANDATORY PROCEDURE
WARNING
propriate safety equipment must be worn. To avoid injury to
FIGURE 50: Install the complete arm.
FIGURE 48: Lubricate the O-ring and position the cylinder on

the studs and fastening.
FIGURE 51: Torque wrench setting: 283 - 312 N·m.
NOTE:

ASSEMBLY
FIGURE 52: Refer and keep to the positions marked during

disassembly.
FIGURE 53: Tighten screws in sequence and a little at a time.

Lock screws with a dynamometric wrench.
Torque wrench setting: 48-53 N·m.

NO-SPIN DIFFERENTIAL UNIT
EXPLODED VIEW
8
5

DISASSEMBLY
DISASSEMBLY
2
CAUTION
CAUTION
any component containing fluids. Dispose of all fluids fol- FIGURE 2: Remove the screws (2) of the ring gear (3).
lowing legal and local regulations. Write down the position of assembly.
CAUTION
skin contact. 3
CAUTION
If disassembly is carried out in order to replace ring gear and
pinion, bearings, or planetary gear, break up distance wa- 4
shers and calculate clearances as indicated in the sections
regarding removal, disassembly, assembly and installation
of differential unit and bevel pinion.
FIGURE 3: Using a punch, remove the ring gear (3).

8
1
7
FIGURE 1: If the bearing needs replacing, extract the bea-

rings (1, 8) from the differential carrier (4, 6).
FIGURE 4: Make positional match marks on the half boxes of
the differential gear (4, 6); loosen and remove capscrews (7).

DISASSEMBLY
FIGURE 5: Using a plastic hammer, disjoin the half box (4, 6).
NOTE:
Note the coupling marks.
FIGURE 6: Extract the no-spin unit (5).

ASSEMBLY
ASSEMBLY
7
4
FIGURE 9: Fit the complete differential unit in a vice and
tighten the screws (7) holding the two half boxes together to
FIGURE 7: Fit the no-spin unit (5) into the differential unit half a torque of 40 N·m.
box (6).
CAUTION
Use only new screws pre-treated with Driloc locking adhe-
sive. Threads must be cleaned from oil. Degrease only non
6 pre-treated threads.
CAUTION
5 Tighten screws using the criss-cross method.
FIGURE 8: Assemble the half box pieces (4, 6). 3
CAUTION
The match marks on the two half-boxes must correspond. 4
FIGURE 10: Install the ring gear (3).
CAUTION
If the ring gear has been replaced, reinstate clearances.

ASSEMBLY
FIGURE 11: Position the ring gear (3) on the differential carrier
and lock it with screws (2).
Torque wrench setting: 135 N·m.
CAUTION
pre-treated threads.
1 8
FIGURE 12: Heat the bearings (1, 8) to about 212°F (100°C)

and fit it to the differential box (4, 6).
WARNING

LIMITED SLIP DIFFERENTIAL UNIT
EXPLODED VIEW
15
3 13
5 10
4
19
16 13
11
14
17 18 15
16 7
14
12 18 11 6
6
14
19 10
15 7 16
14
13 16
7 17
12 9
13 8
1
18 15
11
19 7
10
18
11
19
10
2

DISASSEMBLY
DISASSEMBLY
CAUTION
3
4
CAUTION
any component containing fluids. Dispose of all fluids fol- FIGURE 2: Remove the check screws (3) of the crown (4).
NOTE:
Write down the position of the niches of the central hole
CAUTION in relation to the protrusions of the friction unit steel di-
scs.
skin contact.
CAUTION
5
If disassembly is carried out in order to replace ring gear and
pinion, bearings, or planetary gear, break up distance wa-
shers and calculate clearances as indicated in the sections
regarding removal, disassembly, assembly and installation
of differential unit and bevel pinion.
4
1
FIGURE 3: If bearing (5) needs replacing, remove it; remove
crown (4).
2 7
FIGURE 1: Remove the whole differential unit (2) from the 6

central axle unit (1).
For details, see DIFFERENTIAL UNIT p. 55.
FIGURE 4: Remove the planetary gear (6) and the whole fric-
tion unit (7).

DISASSEMBLY
T9
T1 4
8 12 12
FIGURE 5: If bearing (8) needs replacing, extract it from the FIGURE 7: Introduce tool T9 (For detail see T9 p. 107) in-
differential unit (9). between the planetary gears (12).
10 11
9
11
FIGURE 6: Remove the snap rings (10) from the pins (11) of FIGURE 8: Using two pin-drivers, engage tool T9 (for detail
the planetary gears (12). see T9 p. 107) in between the planetary gears (12).
CAUTION CAUTION
MANDATORY PROCEDURE Carefully check that tool T9 (for detail see T9 p. 107) keeps
Set the pliers following the correct procedure shown in in an aligned position with the pins (11) when locked.
T16A
T11A
T1 5
T10
WARNING
T16A
T11A
FIGURE 9: Place the differential unit (9) under a press, posi-

tion guide bushing T10 (for detail see T10 p. 108) and insert
press tool T11A (See drawing T11 p. 109). Press press tool
T11A (See drawing T11 p. 109) to end of stroke.

DISASSEMBLY
T16A
T11A
T1 5
T10 6
FIGURE 10: Remove press tool T11A (for detail see T11 FIGURE 13: Remove tool T9 (for detail seeT9 p. 107) and ex-
p. 109) and bushing T10 (for detail see T10 p. 108). tract from the differential unit (9) the two final planetary gears
(12), the 2nd differential side gear (6) and the whole friction
NOTE: assembly concerned (7).
In this state, the pin (11) is contained within tool T9 (for
detail see T9 p. 107).
FIGURE 11: Remove tool T9 (for detail see T9 p. 107) and pla-
netary pin (11) with it.
T1
T94
12
12
FIGURE 12: Leaving the released planetary in its position,

lock again tool T9 (for detail see T9 p. 107).
Repeat pin extraction operation on the second planetary pin
(11).
Repeat the same operations on the remaining pins.

ASSEMBLY
ASSEMBLY
18, 2 ± 0,1
6
6
13 14
6
9
15
16
FIGURE 16: 45% FRICTION UNIT COMPOSITION
Friction ring with inner disc (13), intermediate discs (14) and
FIGURE 14: Place the friction disc assembly (7) suitable for friction discs (15) alternated, outer disc (16) and spacer (17).
the specific type of slipping and differential side gear (6) into In case of new discs pack (as spare part), dip the complete
the differential unit (9). disc pack in oil (with LS additive) at least 8 hours (plus 2 drip-
The composition of the unit is illustrated in the points below. ping hours) before assembly, for details about oil see MAIN-
TENANCE INTERVALS p. 14.
18, 2 ± 0,1
6 CAUTION
13
14 As to rings (13, 16), the side without notches must face ou-
twards.
6 17
12
15
16 18
FIGURE 15: 25% FRICTION UNIT COMPOSITION

T16C
T11C
Friction ring with inner disc (13), intermediate discs (14) and
friction discs (15) alternated, outer disc (16) and spacer (17).
In case of new discs pack (as spare part), dip the complete
disc pack in oil (with LS additive) at least 8 hours (plus 2 drip-
ping hours) before assembly, for details about oil see MAIN-
TENANCE INTERVALS p. 14.
FIGURE 17: Position shim washer (18) and the first planetary
gear (12). Hold in position with bar T11C (for detail see T11
p. 109).
CAUTION
As to rings (13, 16), the side without notches must face ou-
twards.

ASSEMBLY
12 19 11
T16A
T11A
18 9
T16C
T11C
FIGURE 18: Using press tool T11A (for detail see T11 p. 109), FIGURE 21: Fit snap rings (19) onto the pins (11).
position the second planetary gear (12) and relative shim wa-
sher (18).
11
T1 5
T10
T1
T94
T16C
T11C 9
FIGURE 22: Position the differential unit (9) under the press,
position bushing T10 (for detail see T10 p. 108) and insert the
FIGURE 19: Insert tool T9 (for detail see T9 p. 107) in-betwe- planetary pin (11).
en the two planetary gears (12). Align the whole unit, pushing
bar T11C (for detail see T11 p. 109) in as far as it will go, until
press tool T11A (for detail see T11 p. 109) is expelled. T16B
T11B 11
T1 5
T10
T1
T94 T16B
T11B
11
6 6
FIGURE 23: Place press tool T11B (for detail see T11 p. 109)
on top of the planetary pin (11).
FIGURE 20: Lock tool T9 (for detail see T9 p. 107) behind the
planetary gears (12). After locking the tool, remove bar T11C
(for detail see T11 p. 109).

ASSEMBLY
T16A
T11A T1 5
T10
7
T16A
T11A
11 6
9
9
FIGURE 24: Press press tool T11B (for detail see T11 p. 109) FIGURE 26: Check that planetary have a light clearance in re-
as far down as it will go. lation to the first planetary gear.
Position the second differential side gear (6) and the second
friction disc assembly (7) into the differential unit (9).
10
3
11 4
FIGURE 25: Remove press tool T11B (for detail see T11 9
p. 109), bushing T10 (for detail see T10 p. 108) and fit the
snap ring (10) onto the pin (11). FIGURE 27: Line the lubrication holes up with the slots in the
differential carrier. Orient the holes of the crown (4) towards
the notches of the braking unit. Position the crown (4) on the
CAUTION differential unit (9) and lock it with the screws (3) previously
coated with Loctite 242.
MANDATORY PROCEDURE Torque wrench setting for screws: 128 - 142 N·m.
END-STOP PLIER SETTING p. 13. NOTE:
Tighten screws using the criss-cross method.
WARNING
T1 7
T12 8
T1 7
T12 5
CAUTION
Make sure that the snap ring centers seat and positions it-
self on the differential unit face.
Repeat the operations on the other planetary pins.
FIGURE 28: If bearings (5, 8) have been removed, install them

using tool T12 (for detail see T12 p. 110).

ASSEMBLY
FIGURE 29: Install the whole differential assembly (2) into the
central body (1).
For details, see DIFFERENTIAL UNIT p. 55

BEVEL PINION
EXPLODED VIEW
22
24
23 26
21
20
25
27
28
16
14
12 37
10
15
8 35
5 13 38
3 33
2 11
1 9 31
19 36 29
34
7
6 32
4
18
17 30

DISASSEMBLY
DISASSEMBLY
32
CAUTION
CAUTION
any component containing fluids. Dispose of all fluids fol- FIGURE 3: Use a screwdriver to remove the o-ring (32).
CAUTION
Hot oil and components can cause personal injury. Avoid 35
skin contact.
29
FIGURE 4: Remove the capscrews (35) from the middle cover

(36).
36
FIGURE 1: Connect a suitable lifting system.

Loosen and remove the screws (29) securing the arm to the
central housing.
31
30
FIGURE 5: Insert a screwdriver in the opposing slots then for-
ce and remove the middle cover (36).
FIGURE 2: Remove the arm (30).

DISASSEMBLY
38
33
FIGURE 6: Mark the position of the ring nuts (34). Remove the FIGURE 9: If the bearings need replacing, extract the external
capscrews (33) from the ring nuts (34). thrust blocks of the bearings (38) from middle cover.
T8
34
FIGURE 7: Apply tool T8 (See drawing T8 p. 107) and remove FIGURE 10: Extract the complete differential unit.
the ring nuts.
NOTE: 22
Accurately clean the threaded portions on ring nuts of
body and cover.
37
FIGURE 11: Connect a suitable lifting system.

Loosen and remove the screws (22) securing the arm (23) to
the central housing.
FIGURE 8: Use a screwdriver to remove the o-ring (37)

DISASSEMBLY
24
27
T8
FIGURE 12: Remove the arm (23) FIGURE 15: Apply tool T8 (See drawing T8 p. 107) and remo-
ve the ring nuts.
NOTE:
25 Accurately clean the threaded portions on ring nuts of
body and cover.
28
FIGURE 13: Use a screwdriver to remove the o-ring (25)
FIGURE 16: If the bearings need replacing, extract the exter-

nal thrust blocks of the bearings (28) from central body.
26
1
FIGURE 14: Mark the position of the ring nuts (27). Remove
the capscrews (26) from the ring nuts (27).
FIGURE 17: Loosen and remove screws (1) locking the cover
(2).
Using a plastic hammer, remove the cover (2) and move it
away.

DISASSEMBLY
FIGURE 18: Use a screwdriver to remove the o-ring (3). FIGURE 21: Remove the driving gear (9) complete with bea-
ring (10).
5 NOTE:
To remove the gear (9) use a lever.
10
6
4
FIGURE 19: Loosen and remove screws (4, 5) and the wa- 9
shers (6) locking the cover (7).
FIGURE 22: Take the driving gear to pieces (9) extracting the
bearing (10).
FIGURE 20: Using a plastic hammer, remove the cover (7)

and move it away.

DISASSEMBLY
T5
FIGURE 23: Remove the snap ring (8). FIGURE 25: Place a block of tender material (aluminium, etc.)
between the reduction body and the gear (11) of the pinion.
Using special tool T5 (see drawing T5 p. 103), remove the ring
CAUTION nut (11).
MANDATORY PROCEDURE
WARNING 12
11
11
FIGURE 26: Remove the ring nut (11) and the gear (12) from
the pinion (19).
FIGURE 24: Remove the calking in order to avoid the screw

cutting the pinion during the ring nut (11) removal.
19
FIGURE 27: Using a plastic hammer, remove the pinion (19).

DISASSEMBLY
15 16
17
13
19
19
FIGURE 28: Remove spacer (15) and shims (16) from the pi- FIGURE 31: Using an internal extractor, remove the bearing
nion (19). thrust block (18) as well as the shim washers (17).
18
14
19
FIGURE 29: Using a puller and a press, remove the inner be- FIGURE 32: Using an internal extractor, remove the seal ring
aring (18) from the pinion (19). (14)
CAUTION
Take care not to damage the seal ring seating.
13
FIGURE 30: Extract the bearing (13)

ASSEMBLY
ASSEMBLY
18
14
FIGURE 35: Bring inner bearing (18) complete with thrust

block, under comparator.
FIGURE 33: Lubricate and install the sealing ring (14) on a su- EXAMPLE: 38 - 1,50 = 36,50 = “D”.
itable diameter tool.
Install the ring in its seat.
CAUTION
Press the thrust block centrally and carry out several mea-
CAUTION surements by rotating the thrust block.
Fill the 30 - 50% of the seal ring (14) lips using Polymer 400
grease.
19
FIGURE 36: Check nominal dimension “I” as marked on the

pinion. Add up to or subtract from “I” the variation indicated
FIGURE 34: Using a faceplate, reset a centesimal compara- as “Y ” to obtain the actual centre distance “I”.
tor on a calibrated block (whose known thickness is 38 mm). EXAMPLE: I = INT ± Y = 133 - 0,1 = 132,9 mm
Preload the comparator by about 3 mm.

ASSEMBLY
17
T6
FIGURE 37: Calculate shims “S” for insertion under the thrust FIGURE 39: Connect the tension rod to the press and move
block of the inner bearing using the following formula: the thrust block of bearings (13, 18) into the seats.
S = X - (I + D) where: X = fixed dimension Disconnect the press and remove the tension rod.
I = actual pinion centre distance
D = Total bearing thickness; NOTE:
EXAMPLE: S = 170,2 - (132,9 + 36,50) = 0,80 mm
Before starting the next stage, make sure that the thrust
block has been completely inserted into its seat.
T6
13
T7
15
18
18 T6
T7
FIGURE 38: Using special tool T6 (See drawing T6 p. 105) 13
partially insert the thrust block of the bearings (13, 18) and FIGURE 40: Introduce tool T7 (See drawing T7 p. 106) com-
shims (17). plete with bearings (13, 18) into the central housing; tighten
by hand until a rolling torque is definitely obtained.
T7
FIGURE 41: Introduce the tracer of a depth comparator into
either side hole of tool T7 (See drawing T7 p. 106). Reset the
comparator with a preload of about 3 mm.

ASSEMBLY
18 T7
18
T7 19
13
FIGURE 42: Remove the depth gauge and release tools and FIGURE 45: Heat the inner bearing (18) to about 212°F
bearings from the central body. (100°C) and fit it to the pinion (19).
Re-install all and insert the spacer (15) between bearings (13,
18); manually tighten the whole pack.
WARNING
T7 16 15
18
15
13
19 19
T7
FIGURE 43: Insert depth gauge into tool T7 (See drawing T7

p. 106) and measure variation "H" in relation to the zero set-
ting performed back at figure 41.
FIGURE 46: Install the complete spacer pack (15, 16) onto
the pinion.
16
19
FIGURE 44: The variation is to be added to a set value of 0.12
- 0.13 mm., so as to obtain the size of shim "S1" (16) which
will be inserted between the bearing (18) and the spacer (15) FIGURE 47: Fit the pinion (19) in the central housing.
and subsequently, to determine the preload for the bearings.

ASSEMBLY
13
FIGURE 48: Heat the outer bearing (13) to a temperature of FIGURE 51: Apply onto the pinion (19) the bar-hold and using
about 176°F (80°C) and fit it on to the pinion (19). a torque metre, check the torque of the pinion.
Torque: 120 - 170 N·cm.
WARNING
CAUTION
If torque exceeds the maximum value, then the size of shim
"S1" (16) needs to be increased.
If torque does not reach the minimum value, then the size of
shim "S1" (16) needs to be reduced.
12 CAUTION
11
If bearings are not new, check the static torque; if bearings
are new, check the continuous torque.
11
FIGURE 49: Install the gear (12) on the pinion (19).

Apply Loctite 243 to threaded portion of the ring nut (11), and
install it.
T5
FIGURE 52: Caulk the ring nut (11).
CAUTION
If the ring nut (11) is re-used, caulk the second position.
Do not re-caulk the same portion.
FIGURE 50: Place a block of tender material (aluminium, etc.)

between the reduction body and the gear (11) of the pinion.
Using special tool T5 (see drawing T5 p. 103), righten the ring
nut (11) to a torque of 800 - 1000 N·m.

ASSEMBLY
28
FIGURE 53: If the bearings are replaced, insert the external FIGURE 56: Install the complete differential unit.
thrust blocks (28) in the central body.
36
38
36
FIGURE 57: Fit the middle cover (36)

FIGURE 54: If the bearings are replaced, insert the external
thrust blocks (38) in the middle cover.
37 35
36
FIGURE 58: Lock the middle cover (36) with screws (35).
Torque wrench setting for screw: 129 - 143 N·m.
FIGURE 55: Lubricate with grease and replace the outer o-
ring (37)
CAUTION

ASSEMBLY
34
T8
FIGURE 59: Spread Loctite 243 on the threaded portion. FIGURE 61: Attach a torque meter to check the rolling torque
Tighten ring nuts (34) on the crown side until clearance increases by 20 - 40 N·cm relative to the rolling torque for the
between pinion and crown is zero, then lock the crown; go pinion bearings measured previously, as a result of the prelo-
back 1/4 - 1/2 turn. ad of the differential bearings.
Example: pinion torque: 120 - 170 N·cm.
Pinion + differential torque: 140 - 170 N·m.
27
CAUTION
T8
If bearings are not new, check the static torque; if bearings
are new, check the continuous torque.
FIGURE 60: Spread Loctite 243 on the threaded portion.

Tighten ring nuts (27) on the ring gear opposite side until the
rolling torque measured on pinion is into required range.
NOTE:
Perform this operation before Loctite polymerizes. Check
polymerize time of the manufacturer operation instruc-
tions.
FIGURE 62: Introduce a dial indicator with rotary key through
the plug hole (20).
Position the dial indicator on the center of one of the teeth of
the crown, pre-set it to 1mm and reset it.
Manually move the crown in both directions in order to check
the existing backlash between the pinion and the crown.

ASSEMBLY
T8
T8 20
21
FIGURE 63: Adjust the backlash between the pinion and the FIGURE 65: Using a driver, fit the cap (20) and position it in
crown by unloosing one of the ring nuts (27, 34) and tighte- its seat with the snap ring (21)
ning the opposite to compensate.
Normal backlash: 0,13 - 0,20 mm.
CAUTION
MANDATORY PROCEDURE
33 26
WARNING
FIGURE 64: Apply Loctite 243 to the screws (26, 33) fit them 25
into one of the two holes and tighten.
CAUTION
FIGURE 66: Insert a new o-ring (25) on the centering diameter

of the arm.

ASSEMBLY
31
24
FIGURE 67: Position the arm (23) on the central housing. FIGURE 70: Position the arm (30) on the central housing.
22 29
FIGURE 68: Spread Loctite 243 on the threaded portion. FIGURE 71: Spread Loctite 243 on the threaded portion.
Tighten the screws (22) in two stages, using the criss-cross Tighten screws (29) in two stages, using the criss-cross me-
method. thod.
Torque wrench setting: 283 - 312 N·m. Torque wrench setting: 283 - 312 N·m.
32
FIGURE 69: Insert a new o-ring (32) on the centering diameter

of the arm.

ASSEMBLY
FIGURE 72: Install the snap ring (8). FIGURE 74: Insert the upper gear unit (9) into the body of the
reduction gear
CAUTION
MANDATORY PROCEDURE
Set the pliers following the correct procedure shown in 7
WARNING
FIGURE 75: Apply Loctite 510 to the locking surface of the

body of the reduction gear.
10 Fit cover (7) and set cover (if necessary) by lightly tapping with
a plastic hammer.
5
9
FIGURE 73: Using a press, fit the bearing (10) on the upper
gear (9)
4 6
FIGURE 76: Spread Loctite 243 on the threaded portion.

Block cover (7) with screws (4, 5) and relative washers (6).

ASSEMBLY
FIGURE 77: Lubricate with grease and replace the outer o-

ring (3).
FIGURE 78: Spread Loctite 243.

Lock the cover (2) with screws (1).
Torque wrench setting for screw: 253 - 312 N·m

SPECIAL TOOLS
SPECIAL TOOLS
T1
50 20
= =
20
=
170
50
=
50
60
260
180
960
20
1010

SPECIAL TOOLS
T2
¯158.5
] ¯158.5
¯50 H7 20˚ ¯35

¯30
0.8
16
0.8
R3
113
-- 0.3
-- 0.5
129
117
R3
148
102
¯132
R5 20˚
100
25
R3
8x15˚
¯40
¯140
-- 0.08
¯50 -- 0.12
¯150
]
¯200 ±0.03
¯95

SPECIAL TOOLS
T3
¯40
2 x45˚
120
1x45˚
0.8
1---- 0.2
0.3
41
26
19
0.8 0.8
5.5
0.8
5x15˚
0
¯139.5 -- 0.1
¯153
¯168
¯180

SPECIAL TOOLS
T4
¯30
3x45
30
130
136.5
1.5 x45
1 0
R
10
R1 0.8
45H7
0.8
6.5
54.5

SPECIAL TOOLS
T5
T5A
48
23 20 20
4 5x15° 5x15°
M5
Ø55 -0,2
Ø36
Ø40
Ø36
Ø15
Ø16
Ø28
Ø7
-0,1
5
18
101
32,6 76 13,5
0
59,5 +0,3
R3
6 -0,2
5,5
0
Ø70
Ø55H8
Ø80
65
.5
59,5 +0,3
R2
,5
0
15°
15°
265
200
45°
5°
10
50 8 10
60

SPECIAL TOOLS
T5B
n 90
n 65
54 H7-g6
48
40
30 °
35
25
30
72
10
20
15
M14
38
50
Ø22
Ø40
Ø55
24
,5
R2
8
Ø4
5
R1

SPECIAL TOOLS
T6
n 35
n 42
-0.08 10.5
n 19.5 -0.12
18.19
R
2
-0.08
n 82 -0.12
n 78.5
n 69 H7
20
35
38.5
R1
5
10
2.5 H11
147
n 55
n 72
185
114
n 15
590
23
550
R2
n 19.5 H8
21 °
n 80
n 82
n 88
n 82
n 80
n 35
-0.1
n 17.5 -0.3
n 19.5 H8
5 _ 15 °
R 10
21 °
30
R
5
R2
M19 x1,5
53
40
75
113
10
23
R5
10 _ 15°
50
-0.1
n 17.5 -0.3
n 40
ZIGRINARE
n 40
n 88
30
R2
M19 x1,5
n 90
n 82 H8
35
R
50
5
10 _ 15°
-0.1
n 107 -0.2

SPECIAL TOOLS
T7
4 x45
15
14
40 300
¯20 ¯1 10
M14 x1 ¯65
M14 x1
20
25 25
50
61-- 0.02
-- 0.01
R5
41
30
¯41.2 +0
-- 0.03 ¯20
¯9
195
95
¯1 1
35
10
50
¯80
¯6.5

SPECIAL TOOLS
T8
57,2
15
3,5
15°
-0,1
Ø35,5 -0,2
Ø22 +0,2
+0,1
Ø19 +0,3
Ø24 H7
Ø25,2
Ø21
139
45
1,2 H11
119
2 30
62 31 54,2
58 12
3x15°
2,5 1,2
54,5
25
R5
R5
118 ±0,1
Ø19 g6
50
Ø145
Ø35,5
Ø21,5
Ø18
Ø24
Ø25
Ø33
Ø44
0
-0,1
Ø14,5 -0,2
R1
Ø15 H7-n6
30
18 184
222
T9
33 36
31 5
6 9 18
26
1 x45 q
0.8
0.8
R1
M26X1.5
Ø20
Ø20
Ø41
Ø25
Ø41
Ø25
+ 0.2
+ 0.2
0.8 0.8
0
0
6
Ø5.5 20 1 x45 q
10.5 22.5 Ø5.5

SPECIAL TOOLS
T10
0.0.1
24.5
8.5
0.8
5
15 q
+ 0.08
+ 0.12
-- 0.1
-- 0.2
Ø23
Ø30
Ø27
Ø20
0.8

SPECIAL TOOLS
T11
T11A
3x30q
r 0.2
Ø19.9 - 0 .1
+0
Ø28.5
10 46.45 r 0.1
56.6
T11B
2x30q
Ø19.9 - 0 .1
+0
Ø30
Ø6
10 19.6
r 0.5
29.6 0.5x45q
T11C
Ø19.9 - 0 1
+0
1x30q
175

SPECIAL TOOLS
T12
0.8
Ø38.5
Ø63
Ø65
Ø55
-- 0.2
-- 0.1
0.8
1 1.5 x45°
0.8
38
68

Copyright 2021 Dana Incorporated For product inquiries or support,
All content is subject to copyright by Dana and may not visit www.dana.com.
be reproduced in whole or in part by any means, For other service publications, visit
electronic or otherwise, without prior written approval. www.danaaftermarket.com/literature-library
THIS INFORMATION IS NOT INTENDED FOR SALE OR For online service parts ordering,
RESALE, AND THIS NOTICE MUST REMAIN ON ALL visit www.danaaftermarket.com
COPIES.

192 Service Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

192 Service Manual

Uploaded by

Copyright:

Available Formats

192 Axle

© Copyright 2021 Dana Incorporated

ASM-0017E - 192 Axle Service Manual Dana Incorporated 3

4 Dana Incorporated ASM-0017E - 192 Axle Service Manual

ASM-0017E - 192 Axle Service Manual Dana Incorporated 5

FILE NAME REVISION DATE CHANGES DESCRIPTION

MANUAL APPLICABILITY AND SUPPORTED MODELS

6 Dana Incorporated ASM-0017E - 192 Axle Service Manual

TYPE SERIAL No.

MANUFACTURED BY DANA ITALIA S.p.a.

ASM-0017E - 192 Axle Service Manual Dana Incorporated 7

Atm Bar MPa Pa PSI

Atm 1 1 0,1 105 14,4

Bar 1 1 0,1 105 14,4

Pa 0,00001 0,00001 10-6 1 -

1N 1 0,1 0,001 0,102 0,225

1daN 10 1 0,01 1,02 2,25

1kN 1000 100 1 102 225

1kg 9,81 0,981 0,00981 1 2,205

N·m daN·m kN·m kg·m lb·in

1N·m 1 0,1 0,001 0,102 8,854

1daN·m 10 1 0,01 1,02 88,54

1kN·m 1000 100 1 102 8854

1kg·m 9,81 0,981 0,00981 1 86,8

1 lb·in 0,1129 0,01129 0,0001129 0,01152 1

8 Dana Incorporated ASM-0017E - 192 Axle Service Manual

SIZE OF BOLT TYPE OF BOLT

M10 x 1,5 mm 48 - 53 N·m 52 - 58 N·m 68 - 75 N·m 73 - 81 N·m 80 - 88 N·m 88 - 97 N·m

SIZE OF BOLT TYPE OF BOLT

ASM-0017E - 192 Axle Service Manual Dana Incorporated 9

WHEEL NUT TIGHTENING TORQUES

WHEEL NUT TIGHTENING TORQUES

RECOMMENDED WHEEL NUTS TORQUE

CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY

M18X1,5 mm 330 N·m 460 N·m

FLAT COLLAR WHEEL M18X1,5 mm 270 N·m 360 N·m

M18X1,5 mm 260 N·m 360 N·m

**RIM'S MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATION. IT IS THE OPTIMUM MA-

10 Dana Incorporated ASM-0017E - 192 Axle Service Manual

ASM-0017E - 192 Axle Service Manual Dana Incorporated 11

OIL DRAINING MANDATORY PROCEDURE

PLANETARY GEAR REDUCTION

12 Dana Incorporated ASM-0017E - 192 Axle Service Manual

END-STOP PLIER SETTING

ASM-0017E - 192 Axle Service Manual Dana Incorporated 13

Only gears - UTTO J20/C, or * in accordance with Machine Service

King Pin Tapered Roller

Trunnion Bushings 10 whs

LUBRICANT & SEALANT SPECIFICATIONS

ASM-0017E - 192 Axle Service Manual Dana Incorporated 15

Indicates an imminently hazardous situation

Indicates information which may make product

16 Dana Incorporated ASM-0017E - 192 Axle Service Manual

ASM-0017E - 192 Axle Service Manual Dana Incorporated 17

FIGURE 1: REPLACING THE BRAKING DISKS

FIGURE 5: Move the cylinder (5) outwards while supporting

18 Dana Incorporated ASM-0017E - 192 Axle Service Manual

FIGURE 8: Slowly introduce low-pressure compressed air

ASM-0017E - 192 Axle Service Manual Dana Incorporated 19

FIGURE 13: Remove pinion (16) complete with O-ring.

FIGURE 14: Unscrew and extract the braking disk clearance

20 Dana Incorporated ASM-0017E - 192 Axle Service Manual

9 FIGURE 4: Lightly lubricate the first steel braking disk (17),

FIGURE 6: Lubricate the first friction disk (8) and install it on